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JP2004087854A - Magnetic device and its manufacturing method - Google Patents

Magnetic device and its manufacturing method Download PDF

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Publication number
JP2004087854A
JP2004087854A JP2002247834A JP2002247834A JP2004087854A JP 2004087854 A JP2004087854 A JP 2004087854A JP 2002247834 A JP2002247834 A JP 2002247834A JP 2002247834 A JP2002247834 A JP 2002247834A JP 2004087854 A JP2004087854 A JP 2004087854A
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Japan
Prior art keywords
metal plate
bus bar
magnetic core
leg
magnetic
Prior art date
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JP2002247834A
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Japanese (ja)
Inventor
Masafumi Itonaga
糸長　雅文
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Panasonic Electric Works Co Ltd
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Matsushita Electric Works Ltd
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Priority to JP2002247834A priority Critical patent/JP2004087854A/en
Publication of JP2004087854A publication Critical patent/JP2004087854A/en
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  • Manufacturing Cores, Coils, And Magnets (AREA)

Abstract

<P>PROBLEM TO BE SOLVED: To provide a magnetic device which has a large current carrying capacity and can be reduced in manufacturing time, and also to provide a method of manufacturing the same. <P>SOLUTION: The magnetic device A is such that an annular magnetic substance core 3 having a nearly rectangular cross-sectional shape is wound with a coil component constituted of two kinds of bus bars 1 and 2 formed out of metal strips. The first bus bar 1 is folded into a form having a nearly U-shaped cross-sectional shape, with the magnetic substance core 3 located between leg pieces 1a and 1b on both sides. A plurality of the first bus bars 1 are arranged with prescribed intervals in the core direction of the magnetic substance core 3. The second bus bar 2 is also folded into a form having a nearly U-shaped cross-sectional shape. A plurality of the second bus bars 2 are arranged, with a central piece 2c being placed on a face of the magnetic substance core 3 facing the opening side of the leg pieces 1a and 1b of the first bus bar 1. One leg piece 1a of the first bus bar 1 and one leg piece 2a of the second bus bar 2 are welded, while at the same time the other leg piece 1b of the first bus bar 1 and the other leg piece 2b of the second bus bar 2 are welded, to form the coil component. <P>COPYRIGHT: (C)2004,JPO

Description

【０００１】
【発明の属する技術分野】
本発明は、磁性体コアにコイルを巻回してなる磁気装置およびその製造方法に関するものである。
【０００２】
【従来の技術】
図１１は従来の磁気装置の一例を示す図であり、環状の磁性体コア（継ぎ目なし）１００にコイル線２００が巻回されている。図１１のような環状の磁性体コア１００に電流容量が大きいコイル線２００を巻回する場合、手作業でコイル線２００の巻回を行っていた。
【０００３】
【発明が解決しようとする課題】
しかしながら、手作業でコイル線を巻回するには、巻回できるコイル線の径に限度があり、ある電流容量値以上に対応する径の大きいコイル線を巻くことが困難であった。また、手作業で巻回を行うため時間がかかり、コスト高となるという問題もあった。
【０００４】
本発明は上記問題点に鑑みて為されたものであって、その目的とするところは、電流容量が大きく、また作製時間を短縮できる磁気装置およびその製造方法を提供することにある。
【０００５】
【課題を解決するための手段】
上記目的を達成するために、請求項１の発明は、磁性体コアと、前記磁性体コアに巻回されるコイル部品とを備え、前記コイル部品は、断面略コ字形に折曲され、両側脚片の間に前記磁性体コアを配置して、前記磁性体コアの磁芯方向に所定の間隔をもって複数並設される第１の金属板と、断面略コ字形に折曲され、前記第１の金属板の両側脚片の開口側に面した前記磁性体コアの面に中央片の外側面を載置して複数並設される第２の金属板とからなり、第１の金属板の一方の脚片と第２の金属板の一方の脚片とを溶接し、第１の金属板の他方の脚片と隣接する別の第２の金属板の他方の脚片とを溶接して構成されるものとした。
【０００６】
請求項２の発明は、磁性体コアと、前記磁性体コアに巻回されるコイル部品とを備え、前記コイル部品は、一端部と他端部とが巻回方向と直交する方向に所定のずれを生じながら前記磁性体コアの周囲を取り囲むように折曲され前記磁性体コアの磁芯方向に所定の間隔をもって複数並設される金属板からなり、金属板の前記一端部と、隣接する別の金属板の前記他端部とを溶接して構成されるものとした。
【０００７】
請求項３の発明は、一端部がつなぎ部材に一体化され、つなぎ部材の長手方向に所定の間隔で並行して形成される複数の帯状の金属板を、前記金属板の他端部と隣接する別の金属板の一端部とが、同一平面上で前記つなぎ部材の長手方向と略直交する同一直線上にくるように金属板の途中に屈曲部を設けて金属部材から打ち抜き形成し、各金属板を略コ字形に折曲して、両側脚片の開口側から両側脚片の間に磁性体コアを配置し、各金属板の前記一端部と隣接する別の金属板の前記他端部とが当接するまで各金属板を曲げた後、前記つなぎ部材を分断し、各金属板の前記一端部と隣接する別の金属板の前記他端部とを溶接してコイル部品を形成するものとした。
【０００８】
【発明の実施の形態】
以下、本発明を実施形態１から実施形態２によって説明する。
（実施形態１）
本実施形態の磁気装置Ａを図１に示す。この磁気装置Ａは、断面略長方形の環状の磁性体コア３に、金属板からなる２種類のバスバー１，２を用いて構成されたコイル部品を巻回してなる。
【０００９】
第１のバスバー１は、図２（ａ）〜（ｃ）に示すように、帯状の金属板を断面略コ字形に折曲して形成されると共に、両側脚片１ａ，１ｂに、両側脚片１ａ，１ｂが並行したまま両側脚片１ａ，１ｂの断面の長手方向に互いに遠ざかるように屈曲した屈曲部１ｄ，１ｅを設けて、両側脚片１ａ，１ｂの間に磁性体コア３を配置した時に、両側脚片１ａ，１ｂの先端が磁性体コア３の磁芯方向に所定のずれを生じるように形成されている。また、両側脚片１ａ，１ｂの開口側に面した磁性体コア３の面より、両側脚片１ａ，１ｂの先端が突出するように、両側脚片１ａ，１ｂの長さが設定されている。
【００１０】
尚、図２は、図１（ａ）における磁性体コア３の左側に巻回されるコイル部品を構成する第１のバスバー１の図であり、図１（ａ）における磁性体コア３の右側に巻回されるコイル部品を構成する第１のバスバー１は、図２の第１のバスバー１を中央片１ｃの長手方向と直交する中心線で線対称に構成したものとなっている。
【００１１】
第２のバスバー２は、図３（ａ）〜（ｃ）に示すように、帯状の金属板を断面略コ字形に折曲して形成され、両側脚片２ａ，２ｂの外側面間の長さは、第１のバスバー１の両側脚片１ａ，１ｂの内側面間の長さと略同じで、さらに中央片２ｃの外側面から両側脚片２ａ，２ｂの先端までの長さは、第１のバスバー１の両側脚片１ａ，１ｂ間に磁性体コア３を配置した時の、両側脚片１ａ，１ｂの開口側に面した磁性体コア３の上面から両側脚片１ａ，１ｂの先端までの長さと略同じに設定されている。
【００１２】
第１のバスバー１は、図４に示すように、両側脚片１ａ，１ｂの間に磁性体コア３を配置すると共に、第１のバスバー１の一方の脚片１ａと、隣接する別の第１のバスバー１の他方の脚片１ｂとが、磁性体コア３の短幅方向に並行する直線上にくるようにして、磁性体コア３の磁芯方向（図４（ａ）において磁性体コア３の長手方向）に沿って複数並設される。
【００１３】
その後、図１に示したように、第２のバスバー２が、第１の金属板の両側脚片１ａ，１ｂの開口側に面した磁性体コア３の面に中央片２ｃの外側面を載置すると共に磁性体コア３の短幅方向と並行するように複数並設され、第１のバスバー１の一方の脚片１ａの先端と、第２のバスバー２の一方の脚片２ａの先端とが溶接により接合され、第１のバスバー１の他方の脚片１ｂの先端と、隣接する別の第２のバスバー２の他方の脚片２ｂの先端とが溶接により接合される。
【００１４】
上記のように、第１のバスバー１の一方の脚片１ａと、隣接する別の第１のバスバー１の他方の脚片１ｂとを、第２のバスバー２で接合していくことにより、磁性体コア３に巻回されたコイル部品が構成される。
【００１５】
かかる磁気装置においては、コイル部品がバスバー１，２により構成されているため、電流容量の大きい磁気装置を作製することができる。また、コイル線を手作業で巻回することなく、２種類のバスバー１，２を溶接することによりコイル部品を構成していくので、コイル作製時間も短縮できる。
【００１６】
（実施形態２）
本実施形態の磁気装置Ｂを図５に示す。この磁気装置Ｂは、実施形態１と同様の断面略長方形の環状の磁性体コア３に、金属板からなるバスバー１０を用いて構成されたコイル部品を巻回してなる。
【００１７】
このバスバー１０は、図６（ａ）〜（ｃ）に示すように、帯状の金属板を略コ字形に折曲して形成されると共に、両側脚片１０ａ，１０ｂに、両側脚片１０ａ，１０ｂが並行したまま、両側脚片１０ａ，１０ｂの断面の長手方向に互いに遠ざかるように屈曲した屈曲部１０ｅ，１０ｆを設けて、両側脚片１０ａ，１０ｂの間に磁性体コア３を配置した時に、両側脚片１０ａ，１０ｂの先端が磁性体コア３の磁芯方向に所定のずれを生じるように形成されている。
【００１８】
また、バスバー１０の一方の脚片１０ａの先端１０ｇ（第１の先端１０ｇ）は、バスバー１０を磁性体コア３に巻回した時に、両側脚片１０ａ，１０ｂの開口側に面した磁性体コア３の面より上方に突出する長さに形成されており、またバスバー１０の他方の脚片１０ｂの先端は、バスバー１０を磁性体コア３に巻回した時に、中央片１０ｃと並行するように略直角に折曲され中央対向片１０ｄを形成した後、さらに外側に略直角に折曲され、バスバー１０を磁性体コア３に巻回した時に、一方の脚片１０ａと並行する第２の先端１０ｈを形成している。
【００１９】
尚、図６は、図５（ａ）における磁性体コア３の左側に巻回されるコイル部品を構成するバスバー１０の図であり、図５（ａ）における磁性体コア３の右側に巻回されるコイル部品を構成するバスバー１０は、図６のバスバー１０を中央片１０ｃの長手方向と直交する中心線で線対称に構成したものとなっている。
【００２０】
上記のように形成されたバスバー１０は、図７（ａ）〜（ｃ）に示すように、その両側脚片１０ａ，１０ｂの開口側から両側脚片の間へ磁性体コア３を配置し、バスバー１０の第１の先端１０ｇと、隣接する別のバスバー１０の第２の先端１０ｈとが、磁性体コア３の短幅方向に並行する直線上にくるようにして、磁性体コア３の磁芯方向に沿って複数並設される。
【００２１】
その後、図７（ｃ）に示したように、バスバー１０の第２の先端１０ｈが、隣接する別のバスバー１０の第１の先端１０ｇと当接するまで、バスバー１０の側面１０ｂを矢印α方向へと押して折り曲げた後、第２の先端１０ｈと、隣接する別のバスバー１０の第１の先端１０ｇとを溶接していく。
【００２２】
以上により、第１の先端１０ｇと第２の先端１０ｈとが巻回方向と直交する方向に所定のずれを生じながら磁性体コア３の周囲を取り囲むように折曲され磁性体コア３の磁芯方向に所定の間隔をもって複数並設されるバスバー１０からなりバスバー１０の第１の先端１０ｇと、隣接する別のバスバー１０の他端部１０ｈとを溶接して構成されたコイル部品が出来上がる。
【００２３】
かかる磁気装置においては、実施形態１では第１のバスバー１と第２のバスバー２とから構成されたコイル部品が、バスバー１０のみで構成されており、材料取りがし易いため材料面で効率が良く、また金型も１種類で済むためコストの低減が図れる。また、コイル部品１巻きにつき溶接箇所が１ヶ所で済むため、コイル作製時間が更に短縮できる。
【００２４】
尚、バスバー１０は、単体で磁性体コア３へ設置せずに、つなぎ部材に複数並行した状態でまとめて磁性体コア３へ設置するようにしてもよい。
【００２５】
則ち、図８に示すように、バスバー１０を、第２の先端１０ｈがつなぎ部材２０に一体化され、つなぎ部材の長手方向に所定の間隔で並行する複数の帯状の部材となるようにフープ状の金属部材から打ち抜き形成する。この時、バスバー１０の第１の先端１０ｇと隣接する別のバスバー１０の第２の先端１０ｈとが、同一平面上でつなぎ部材２０の長手方向と略直交する同一直線ｘ上にくるように途中に２ヶ所の屈曲部１０ｅ，１０ｆを設けておく。屈曲部１０ｅ，１０ｆを設ける位置は、バスバー１０を磁性体コア３に巻回した時に、磁性体コア３の両側面と対向する位置とする。
【００２６】
そして、各バスバー１０を、つなぎ部材２０に連結されたままの状態で、図９に示すように、略コ字形に折曲する。また、バスバー１０の他方の脚片１０ｂの先端を、バスバー１０を磁性体コア３に巻回した時に、中央片１０ｃと並行するように略直角に折曲して中央対向片１０ｄを形成した後、さらに外側に略直角に折曲して、バスバー１０を磁性体コア３に巻回した時に、一方の脚片１０ａと並行する第２の先端１０ｈを形成する。
【００２７】
その後、図１０に示すように、両側脚片１０ａ，１０ｂの開口側から両側脚片の間へ磁性体コア３を配置し、バスバー１０の他方の脚片１０ｂを矢印α方向へと押して折り曲げる。
【００２８】
この時、バスバー１０の第２の先端１０ｈと隣接する別のバスバー１０の第１の先端１０ｇとは、バスバー１０をフープ状の金属部材から打ち抜き形成した時に、同一平面上でつなぎ部材２０の長手方向と略直交する同一直線ｘ上にくるように形成されているため、バスバー１０の他方の脚片１０ｂを矢印α方向へと押して折り曲げると、第２の先端１０ｈと隣接する別のバスバー１０の第１の先端１０ｇとが当接する。
【００２９】
その後、つなぎ部材２０を第２の先端１０ｈから分断し、第２の先端１０ｈと、隣接する別のバスバー１０の第１の先端１０ｇとを溶接していく。
【００３０】
かかる製造方法においては、バスバー１０を一括して磁性体コア３へ設置できるため、バスバー１０を磁性体コア３へ設置する工数が削減でき、さらにコイル作製時間を短縮できる。
【００３１】
【発明の効果】
請求項１の発明は、磁性体コアと、前記磁性体コアに巻回されるコイル部品とを備え、前記コイル部品は、断面略コ字形に折曲され、両側脚片の間に前記磁性体コアを配置して、前記磁性体コアの磁芯方向に所定の間隔をもって複数並設される第１の金属板と、断面略コ字形に折曲され、前記第１の金属板の両側脚片の開口側に面した前記磁性体コアの面に中央片の外側面を載置して複数並設される第２の金属板とからなり、第１の金属板の一方の脚片と第２の金属板の一方の脚片とを溶接し、第１の金属板の他方の脚片と隣接する別の第２の金属板の他方の脚片とを溶接して構成されるので、コイル部品が前記第１の金属板と第２の金属板とから構成されているため、電流容量の大きい磁気装置を作製することができ、また前記第１の金属板と第２の金属板とを溶接して巻線化するので、作製時間も短縮できるという効果がある。
【００３２】
請求項２の発明は、磁性体コアと、前記磁性体コアに巻回されるコイル部品とを備え、前記コイル部品は、一端部と他端部とが巻回方向と直交する方向に所定のずれを生じながら前記磁性体コアの周囲を取り囲むように折曲され前記磁性体コアの磁芯方向に所定の間隔をもって複数並設される金属板からなり、金属板の前記一端部と、隣接する別の金属板の前記他端部とを溶接して構成されるので、請求項１記載の発明と同様に、コイル部品が前記金属板から構成されているため電流容量の大きい磁気装置を作製することができると共に、請求項１記載の発明と比較して、コイル部品１巻きにつき溶接箇所が１ヶ所で済むため、作製時間が更に短縮でき、また前記コイル部品が１種類の金属板からなるため、材料面で効率がよく金型も１種類で済むためコストの低減が図れるという効果がある。
【００３３】
請求項３の発明は、一端部がつなぎ部材に一体化され、つなぎ部材の長手方向に所定の間隔で並行して形成される複数の帯状の金属板を、前記金属板の他端部と隣接する別の金属板の一端部とが、同一平面上で前記つなぎ部材の長手方向と略直交する同一直線上にくるように金属板の途中に屈曲部を設けて金属部材から打ち抜き形成し、各金属板を略コ字形に折曲して、両側脚片の開口側から両側脚片の間に磁性体コアを配置し、各金属板の前記一端部と隣接する別の金属板の前記他端部とが当接するまで各金属板を曲げた後、前記つなぎ部材を分断し、各金属板の前記一端部と隣接する別の金属板の前記他端部とを溶接してコイル部品を形成するので、コイル部品が金属板から構成されているため電流容量が大きく、また前記金属板をまとめて前記磁性体コアに巻回できるので作製時間が短縮された磁気装置を製造できるという効果がある。
【図面の簡単な説明】
【図１】（ａ）実施形態１の磁気装置の上面図である。
（ｂ）同上の側面図である。
（ｃ）同上の正面断面図である。
【図２】（ａ）同上の第１のバスバーの上面図である。
（ｂ）同上の側面図である。
（ｃ）同上の正面図である。
【図３】（ａ）同上の第２のバスバーの上面図である。
（ｂ）同上の側面図である。
（ｃ）同上の正面図である。
【図４】（ａ）同上の第１のバスバーを磁性体コアに設置した状態の上面図である。
（ｂ）同上の側面図である。
（ｃ）同上の正面断面図である。
【図５】（ａ）実施形態２の磁気装置の上面図である。
（ｂ）同上の側面図である。
（ｃ）同上の正面断面図である。
【図６】（ａ）同上のバスバーの上面図である。
（ｂ）同上の側面図である。
（ｃ）同上の正面図である。
【図７】（ａ）同上のバスバーを磁性体コアに設置した状態の上面図である。
（ｂ）同上の側面図である。
（ｃ）同上の正面断面図である。
【図８】同上でつなぎ部材に連結された状態のバスバーを示す図である。
【図９】（ａ）同上でつなぎ部材に連結されたまま折曲されたバスバーの上面図である。
（ｂ）同上の側面図である。
（ｃ）同上の正面図である。
【図１０】（ａ）同上でつなぎ部材に連結されたまま磁性体コアに設置されたバスバーの上面図である。
（ｂ）同上の側面図である。
（ｃ）同上の正面断面図である。
【図１１】（ａ）従来例の磁気装置の上面図である。
（ｂ）同上の側面断面図である。
【符号の説明】
１　第１のバスバー
１ａ，１ｂ　脚片
１ｃ　中央片
１ｄ，１ｅ　屈曲部
２　第２のバスバー
２ａ，２ｂ　脚片
２ｃ　中央片
３　磁性体コア
１０　バスバー
１０ａ，１０ｂ　側面
１０ｃ　底面
１０ｄ　上面
１０ｅ，１０ｆ　屈曲部
１０ｇ，１０ｈ　先端
２０　つなぎ部材[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a magnetic device having a coil wound around a magnetic core and a method of manufacturing the magnetic device.
[0002]
[Prior art]
FIG. 11 is a diagram showing an example of a conventional magnetic device, in which a coil wire 200 is wound around an annular magnetic core (without seams) 100. When the coil wire 200 having a large current capacity is wound around the annular magnetic core 100 as shown in FIG. 11, the coil wire 200 is manually wound.
[0003]
[Problems to be solved by the invention]
However, when winding a coil wire manually, there is a limit on the diameter of the coil wire that can be wound, and it has been difficult to wind a coil wire having a large diameter corresponding to a certain current capacity value or more. In addition, there is also a problem that it takes time to perform the winding by hand and the cost is high.
[0004]
The present invention has been made in view of the above problems, and an object of the present invention is to provide a magnetic device having a large current capacity and capable of reducing a manufacturing time, and a method for manufacturing the same.
[0005]
[Means for Solving the Problems]
In order to achieve the above object, a first aspect of the present invention includes a magnetic core, and a coil component wound around the magnetic core, wherein the coil component is bent into a substantially U-shaped cross section, A first metal plate having a plurality of first metal plates arranged in parallel at predetermined intervals in a magnetic core direction of the magnetic core, wherein the magnetic core is disposed between leg pieces; A first metal plate comprising a plurality of second metal plates on which the outer surface of the central piece is placed on the surface of the magnetic core facing the opening sides of the two leg pieces of the first metal plate; Is welded to one leg of the second metal plate, and the other leg of the first metal plate is welded to the other leg of another adjacent second metal plate. It was constituted by.
[0006]
The invention according to claim 2 includes a magnetic core, and a coil component wound around the magnetic core, wherein the coil component has a predetermined direction in a direction in which one end and the other end are orthogonal to the winding direction. A metal plate which is bent so as to surround the periphery of the magnetic core while causing a displacement, and which is arranged in parallel at a predetermined interval in the magnetic core direction of the magnetic core, and which is adjacent to the one end of the metal plate; The other end of the metal plate is welded to the other end.
[0007]
The invention according to claim 3 is such that a plurality of strip-shaped metal plates whose one end is integrated with the connecting member and which are formed in parallel at predetermined intervals in the longitudinal direction of the connecting member are adjacent to the other end of the metal plate. A bent portion is provided in the middle of the metal plate so that one end of another metal plate to be formed is on the same straight line substantially orthogonal to the longitudinal direction of the connecting member on the same plane, and is formed by punching from the metal member. A metal plate is bent into a substantially U-shape, and a magnetic core is arranged between the two leg portions from the opening side of the two leg portions, and the other end of another metal plate adjacent to the one end portion of each metal plate. After bending each metal plate until the portion abuts, the connecting member is divided, and the one end of each metal plate and the other end of another adjacent metal plate are welded to form a coil component. It was taken.
[0008]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, the present invention will be described with reference to Embodiments 1 and 2.
(Embodiment 1)
FIG. 1 shows a magnetic device A of this embodiment. The magnetic device A is formed by winding a coil component formed by using two types of bus bars 1 and 2 made of a metal plate around an annular magnetic core 3 having a substantially rectangular cross section.
[0009]
As shown in FIGS. 2A to 2C, the first bus bar 1 is formed by bending a band-shaped metal plate into a substantially U-shaped cross section, and has two side legs 1a and 1b with two side legs. Bending portions 1d and 1e are provided so as to be bent away from each other in the longitudinal direction of the cross section of both leg pieces 1a and 1b while the pieces 1a and 1b are arranged in parallel, and the magnetic material core 3 is arranged between both leg pieces 1a and 1b. At this time, the ends of the two leg pieces 1a and 1b are formed so as to cause a predetermined displacement in the magnetic core direction of the magnetic core 3. The lengths of the two leg pieces 1a, 1b are set such that the tips of the two leg pieces 1a, 1b project from the surface of the magnetic core 3 facing the opening side of the both leg pieces 1a, 1b. .
[0010]
FIG. 2 is a diagram of the first bus bar 1 constituting a coil component wound around the left side of the magnetic core 3 in FIG. 1A, and is a right side of the magnetic core 3 in FIG. The first bus bar 1 constituting the coil component wound around the first bus bar 1 is configured such that the first bus bar 1 of FIG. 2 is line-symmetric with respect to a center line orthogonal to the longitudinal direction of the central piece 1c.
[0011]
As shown in FIGS. 3A to 3C, the second bus bar 2 is formed by bending a band-shaped metal plate into a substantially U-shaped cross section, and has a length between the outer surfaces of the two leg pieces 2a and 2b. The length is substantially the same as the length between the inner side surfaces of both side leg pieces 1a and 1b of the first bus bar 1, and the length from the outer side surface of the center piece 2c to the tip of both side leg pieces 2a and 2b is the first. When the magnetic core 3 is disposed between the two leg pieces 1a and 1b of the bus bar 1, the upper surface of the magnetic core 3 facing the opening side of the two leg pieces 1a and 1b to the tip of the two leg pieces 1a and 1b. It is set to be almost the same as the length.
[0012]
As shown in FIG. 4, the first bus bar 1 has the magnetic core 3 disposed between the two leg pieces 1a and 1b, and has one leg piece 1a of the first bus bar 1 and another adjacent one. The other leg 1b of the first bus bar 1 is positioned on a straight line parallel to the short width direction of the magnetic core 3 so that the direction of the magnetic core of the magnetic core 3 (the magnetic core in FIG. 3 in the longitudinal direction).
[0013]
Thereafter, as shown in FIG. 1, the second bus bar 2 mounts the outer surface of the central piece 2c on the surface of the magnetic core 3 facing the opening side of the two leg pieces 1a, 1b of the first metal plate. The first bus bar 1 is provided with a plurality of juxtaposed ones in parallel with the short width direction of the magnetic core 3, and a tip of one leg 1 a of the first bus bar 1 and a tip of one leg 2 a of the second bus bar 2. Are joined by welding, and the tip of the other leg 1b of the first bus bar 1 and the tip of the other leg 2b of another adjacent second bus bar 2 are joined by welding.
[0014]
As described above, the one leg 1a of the first bus bar 1 and the other leg 1b of another adjacent first bus bar 1 are joined by the second bus bar 2 so that the magnetic field is increased. A coil component wound around the body core 3 is configured.
[0015]
In such a magnetic device, since the coil component is constituted by the bus bars 1 and 2, a magnetic device having a large current capacity can be manufactured. Further, since the coil component is formed by welding the two types of bus bars 1 and 2 without manually winding the coil wire, the time required to manufacture the coil can be reduced.
[0016]
(Embodiment 2)
FIG. 5 shows a magnetic device B of the present embodiment. The magnetic device B is formed by winding a coil component formed by using a bus bar 10 made of a metal plate around an annular magnetic core 3 having a substantially rectangular cross section as in the first embodiment.
[0017]
As shown in FIGS. 6A to 6C, the bus bar 10 is formed by bending a band-shaped metal plate into a substantially U-shape, and is formed on both side leg pieces 10a and 10b, and on both side leg pieces 10a and 10b. When the magnetic core 3 is disposed between the two leg pieces 10a and 10b by providing the bent parts 10e and 10f which are bent away from each other in the longitudinal direction of the cross section of the both leg pieces 10a and 10b while keeping the 10b parallel. The distal ends of both leg pieces 10a and 10b are formed so as to cause a predetermined displacement in the direction of the magnetic core of the magnetic core 3.
[0018]
When the bus bar 10 is wound around the magnetic core 3, the tip 10 g of the one leg 10 a of the bus bar 10 is wound on the magnetic core 3 and faces the opening of the leg 10 a, 10 b on both sides. 3, and the tip of the other leg 10b of the bus bar 10 is parallel to the center piece 10c when the bus bar 10 is wound around the magnetic core 3. After being bent at a substantially right angle to form the central opposing piece 10d, the second end is bent outward at a substantially right angle, and is parallel to one leg piece 10a when the bus bar 10 is wound around the magnetic core 3. 10h.
[0019]
FIG. 6 is a view of the bus bar 10 constituting a coil component wound on the left side of the magnetic core 3 in FIG. 5A, and is wound on the right side of the magnetic core 3 in FIG. 5A. The bus bar 10 constituting the coil component to be formed has a configuration in which the bus bar 10 of FIG. 6 is symmetrical with respect to a center line orthogonal to the longitudinal direction of the central piece 10c.
[0020]
In the bus bar 10 formed as described above, as shown in FIGS. 7A to 7C, the magnetic core 3 is arranged between the opening sides of the both-side legs 10a and 10b and between the two-side legs. The first tip 10g of the bus bar 10 and the second tip 10h of another adjacent bus bar 10 are on a straight line parallel to the short width direction of the magnetic core 3 so that the magnetic core 3 A plurality are arranged in parallel along the core direction.
[0021]
Thereafter, as shown in FIG. 7C, the side surface 10b of the bus bar 10 is moved in the direction of the arrow α until the second end 10h of the bus bar 10 contacts the first end 10g of another adjacent bus bar 10. Then, the second tip 10h and the first tip 10g of another adjacent bus bar 10 are welded.
[0022]
As described above, the first tip 10g and the second tip 10h are bent so as to surround the magnetic core 3 while causing a predetermined shift in a direction orthogonal to the winding direction. A coil component comprising a plurality of bus bars 10 arranged side by side at predetermined intervals in the direction and welding the first end 10g of the bus bar 10 and the other end 10h of another adjacent bus bar 10 is completed.
[0023]
In such a magnetic device, in the first embodiment, the coil component composed of the first bus bar 1 and the second bus bar 2 is composed only of the bus bar 10, and the material can be easily removed. In addition, the cost can be reduced because only one type of die is required. Further, since only one welding point is required for one turn of the coil component, the coil manufacturing time can be further reduced.
[0024]
Note that the bus bar 10 may not be installed alone on the magnetic core 3, but may be installed on the magnetic core 3 in a state where a plurality of the bus bars 10 are arranged in parallel with the connecting member.
[0025]
That is, as shown in FIG. 8, the bus bar 10 is hooped so that the second tip 10 h is integrated with the connecting member 20 and becomes a plurality of band-shaped members parallel to the connecting member 20 at predetermined intervals in the longitudinal direction. It is stamped and formed from a metal member in a shape. At this time, the first end 10g of the bus bar 10 and the second end 10h of another bus bar 10 adjacent to each other are positioned on the same straight line x substantially orthogonal to the longitudinal direction of the connecting member 20 on the same plane. Are provided with two bent portions 10e and 10f. The positions where the bent portions 10 e and 10 f are provided are positions facing the both side surfaces of the magnetic core 3 when the bus bar 10 is wound around the magnetic core 3.
[0026]
Then, each bus bar 10 is bent in a substantially U-shape while being connected to the connecting member 20, as shown in FIG. After the bus bar 10 is wound around the magnetic core 3, the tip of the other leg 10 b of the bus bar 10 is bent at a substantially right angle so as to be parallel to the center piece 10 c to form a center facing piece 10 d. Further, when the bus bar 10 is bent outwardly at a substantially right angle to wind the bus bar 10 around the magnetic core 3, a second tip 10h is formed in parallel with the one leg 10a.
[0027]
Thereafter, as shown in FIG. 10, the magnetic core 3 is arranged between the opening sides of the two leg pieces 10a and 10b and between the two leg pieces, and the other leg piece 10b of the bus bar 10 is pushed and bent in the direction of the arrow α.
[0028]
At this time, the second end 10h of the bus bar 10 and the first end 10g of the adjacent bus bar 10 are connected to the first end 10g of the adjacent bus bar 10 by punching the bus bar 10 from a hoop-shaped metal member. Since it is formed so as to be on the same straight line x that is substantially perpendicular to the direction, if the other leg 10b of the bus bar 10 is bent by pushing it in the direction of the arrow α, the other end 10h of the adjacent bus bar 10 The first tip 10g comes into contact with the first tip 10g.
[0029]
Thereafter, the connecting member 20 is separated from the second tip 10h, and the second tip 10h and the first tip 10g of another adjacent bus bar 10 are welded.
[0030]
In such a manufacturing method, since the bus bar 10 can be collectively installed on the magnetic core 3, the number of steps for installing the bus bar 10 on the magnetic core 3 can be reduced, and the coil manufacturing time can be further reduced.
[0031]
【The invention's effect】
The invention according to claim 1 comprises a magnetic core and a coil component wound around the magnetic core, wherein the coil component is bent in a substantially U-shaped cross section, and the magnetic material is provided between both leg pieces. A plurality of first metal plates having a plurality of cores arranged side by side at predetermined intervals in the direction of the magnetic core of the magnetic material core, and both side legs of the first metal plate bent in a substantially U-shaped cross section; A plurality of second metal plates placed on the outer surface of the central piece on the surface of the magnetic core facing the opening side of the first metal plate, and one leg piece of the first metal plate and the second metal plate. Is formed by welding one leg of the first metal plate and welding the other leg of the first metal plate and the other leg of the adjacent second metal plate. Is composed of the first metal plate and the second metal plate, a magnetic device having a large current capacity can be manufactured. When since the winding by being welded to the second metal plate, there is an effect that the manufacturing time can be shortened.
[0032]
The invention according to claim 2 includes a magnetic core, and a coil component wound around the magnetic core, wherein the coil component has a predetermined direction in a direction in which one end and the other end are orthogonal to the winding direction. A metal plate which is bent so as to surround the periphery of the magnetic core while causing a displacement, and which is arranged in parallel at a predetermined interval in the magnetic core direction of the magnetic core, and which is adjacent to the one end of the metal plate; Since another coil is formed by welding the other end of the metal plate, a magnetic device having a large current capacity is manufactured because the coil component is formed of the metal plate, similarly to the first aspect of the invention. In addition to the above, the present invention can further reduce the manufacturing time because only one welding point is required for one turn of the coil component as compared with the invention of claim 1, and the coil component is made of one type of metal plate. Efficient material and one type of mold There is an effect that cost reduction can be achieved because it requires.
[0033]
The invention according to claim 3 is such that a plurality of strip-shaped metal plates whose one end is integrated with the connecting member and which are formed in parallel at predetermined intervals in the longitudinal direction of the connecting member are adjacent to the other end of the metal plate. A bent portion is provided in the middle of the metal plate so that one end of another metal plate to be formed is on the same straight line substantially orthogonal to the longitudinal direction of the connecting member on the same plane, and is formed by punching from the metal member. A metal plate is bent into a substantially U-shape, and a magnetic core is arranged between the two leg portions from the opening side of the two leg portions, and the other end of another metal plate adjacent to the one end portion of each metal plate. After bending each metal plate until the portion abuts, the connecting member is divided, and the one end of each metal plate and the other end of another adjacent metal plate are welded to form a coil component. Therefore, since the coil component is formed of a metal plate, the current capacity is large, and the metal plate is Since it can be wound on the magnetic core Te has the effect of a magnetic device manufacturing time is shortened can be produced.
[Brief description of the drawings]
FIG. 1A is a top view of a magnetic device according to a first embodiment.
(B) It is a side view same as the above.
(C) It is a front sectional view same as the above.
FIG. 2A is a top view of a first bus bar of the above.
(B) It is a side view same as the above.
(C) It is a front view same as the above.
FIG. 3A is a top view of a second bus bar of the above.
(B) It is a side view same as the above.
(C) It is a front view same as the above.
FIG. 4A is a top view showing a state in which the first bus bar is mounted on a magnetic core.
(B) It is a side view same as the above.
(C) It is a front sectional view same as the above.
FIG. 5A is a top view of a magnetic device according to a second embodiment.
(B) It is a side view same as the above.
(C) It is a front sectional view same as the above.
FIG. 6A is a top view of the bus bar of the above.
(B) It is a side view same as the above.
(C) It is a front view same as the above.
FIG. 7A is a top view showing a state in which the bus bar is mounted on a magnetic core.
(B) It is a side view same as the above.
(C) It is a front sectional view same as the above.
FIG. 8 is a view showing a bus bar in a state where the bus bar is connected to a connecting member in the same.
FIG. 9 (a) is a top view of the bent bus bar connected to the connecting member in the same.
(B) It is a side view same as the above.
(C) It is a front view same as the above.
FIG. 10 (a) is a top view of a bus bar installed on a magnetic core while being connected to a connecting member in the same.
(B) It is a side view same as the above.
(C) It is a front sectional view same as the above.
FIG. 11A is a top view of a conventional magnetic device.
(B) It is a side sectional view same as the above.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 1st bus bar 1a, 1b Leg piece 1c Central piece 1d, 1e bending part 2 Second bus bar 2a, 2b Leg piece 2c Central piece 3 Magnetic core 10 Bus bar 10a, 10b Side face 10c Bottom face 10d Top face 10e, 10f Bending part 10g, 10h Tip 20 Connecting member

Claims (3)

磁性体コアと、前記磁性体コアに巻回されるコイル部品とを備え、前記コイル部品は、断面略コ字形に折曲され、両側脚片の間に前記磁性体コアを配置して、前記磁性体コアの磁芯方向に所定の間隔をもって複数並設される第１の金属板と、断面略コ字形に折曲され、前記第１の金属板の両側脚片の開口側に面した前記磁性体コアの面に中央片の外側面を載置して複数並設される第２の金属板とからなり、第１の金属板の一方の脚片と第２の金属板の一方の脚片とを溶接し、第１の金属板の他方の脚片と隣接する別の第２の金属板の他方の脚片とを溶接して構成されることを特徴とする磁気装置。A magnetic core, and a coil component wound around the magnetic core, wherein the coil component is bent into a substantially U-shaped cross section, and the magnetic core is disposed between both leg pieces; A plurality of first metal plates arranged side by side at predetermined intervals in the direction of the magnetic core of the magnetic material core; and A plurality of second metal plates are arranged in parallel with the outer surface of the central piece placed on the surface of the magnetic core, and one leg of the first metal plate and one leg of the second metal plate A magnetic device comprising: welding a first piece of metal to another leg of a first metal plate and another leg of another adjacent second metal plate; 磁性体コアと、前記磁性体コアに巻回されるコイル部品とを備え、前記コイル部品は、一端部と他端部とが巻回方向と直交する方向に所定のずれを生じながら前記磁性体コアの周囲を取り囲むように折曲され前記磁性体コアの磁芯方向に所定の間隔をもって複数並設される金属板からなり、金属板の前記一端部と、隣接する別の金属板の前記他端部とを溶接して構成されることを特徴とする磁気装置。A magnetic material core, and a coil component wound around the magnetic material core, wherein the coil component is configured such that the one end portion and the other end portion are separated from each other by a predetermined displacement in a direction orthogonal to a winding direction A plurality of metal plates which are bent so as to surround the periphery of the core and are arranged side by side at predetermined intervals in the direction of the magnetic core of the magnetic material core; A magnetic device characterized by being welded to an end. 一端部がつなぎ部材に一体化され、つなぎ部材の長手方向に所定の間隔で並行して形成される複数の帯状の金属板を、前記金属板の他端部と隣接する別の金属板の一端部とが、同一平面上で前記つなぎ部材の長手方向と略直交する同一直線上にくるように金属板の途中に屈曲部を設けて金属部材から打ち抜き形成し、各金属板を略コ字形に折曲して、両側脚片の開口側から両側脚片の間に磁性体コアを配置し、各金属板の前記一端部と隣接する別の金属板の前記他端部とが当接するまで各金属板を曲げた後、前記つなぎ部材を分断し、各金属板の前記一端部と隣接する別の金属板の前記他端部とを溶接してコイル部品を形成することを特徴とする磁気装置の製造方法。One end portion is integrated with the connecting member, and a plurality of band-shaped metal plates formed in parallel at a predetermined interval in the longitudinal direction of the connecting member are connected to one end of another metal plate adjacent to the other end of the metal plate. Part, a bent portion is provided in the middle of the metal plate so as to be on the same straight line substantially orthogonal to the longitudinal direction of the connecting member on the same plane, and formed by punching from the metal member, and each metal plate is formed into a substantially U-shape. Bend and arrange the magnetic core between the two leg pieces from the opening side of the two leg pieces, until the one end of each metal plate abuts on the other end of another adjacent metal plate. After bending the metal plate, the connecting member is cut off, and the one end of each metal plate and the other end of another adjacent metal plate are welded to form a coil device. Manufacturing method.
JP2002247834A 2002-08-27 2002-08-27 Magnetic device and its manufacturing method Pending JP2004087854A (en)

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